Battelle Team 

Dose Reconstruction 

Project for NIOSH

Document Title: 

Site Profiles for Atomic Weapons Employers that 

Worked Uranium and Thorium Metals 

Appendix R – Aluminum Company of America – 

Pennsylvania (Alcoa 1) 

. 

Document Number: Battelle-TBD-6000 

Appendix R 

Revision: 0 

Effective Date: 4/30/2007 

Type of Document: TBD Appendix

Supersedes: None 

Subject Experts: R.I. Scherpelz, N.J. Heyer 

Document Owner 

Approval: Signature on file Approval Date: 4/24/2007 

Robert I. Scherpelz, Staff Scientist 

Approval: Signature on file Approval Date: 4/24/2007 

Jay A. MacLellan, Battelle PNWD Task Manager 

Concurrence: Signature on file Concurrence Date: 4/24/2007 

Richard J. Traub, Staff Scientist 

Approval: Signature on file Approval Date: 4/27/2007 

James W. Neton, Associate Director of Science 

 New Total Rewrite Revision Page Change 

FOR DOCUMENTS MARKED AS A TOTAL REWRITE, REVISION, OR PAGE CHANGE, REPLACE THE PRIOR 

REVISION AND DISCARD / DESTROY ALL COPIES OF THE PRIOR REVISION. 
Document No. Battelle-TBD-6000; 

Appendix R 

Revision No. 0 Effective Date: 4/30/2007 Page 2 

ALUMINUM COMPANY OF AMERICA – PENNSYLVANIA 

R.1 Introduction 

This document serves as an appendix to Battelle-TBD-6000, Site Profiles for Atomic 

Weapons Employers that Worked Uranium and Thorium Metals. This appendix 

describes the results of document research specific to this site. Where specific 

information is lacking, research into similar facilities described in the body of this Site 

Profile is used. 

R.2 Site Description 

The Atomic Weapons Employer Aluminum Company of America (ALCOA) had one site 

located in New Kensington, Pennsylvania. The facility was also known as Aluminum 

Research Laboratories; or the New Kensington Works (of ALCOA) on Pine and 9th 

Streets. It is listed as an Atomic Weapons Employer from 1943 through 1945. ALCOA 

was one of 14 facilities in the early 1940s that produced nuclear fuel for the X-10 pilot 

plant reactor in Oak Ridge, Tennessee and the production reactors at Hanford, 

Washington. The work was conducted in two buildings (#29 and #44) both of which are 

still standing with relatively little remodeling. (Reference 9557, Pages 8-10) 

R.2.1 Site Activities 

Alcoa used a unique welding process to "can" and seal uranium slugs produced by other 

facilities. Initiated in the spring of 1943, the work preceded under 15 purchase orders that 

resulted in the canning of approximately 100,000 slugs through 1945. Actual machining 

of uranium metal was apparently limited to experimental machine shop and laboratory 

situations. (Reference 9557, Pages 8-10) 

R.2.2 Job Categories 

Each claim will be evaluated to determine the most appropriate Job Category from the list 

below. 

Plant Floor High (Involved directly in operations) 

Machinist (in shop) 

Unknown 

Plant Floor Low (Involved in support of operations) 

Inspector 

Mechanic (for Fork Lift trucks) 

Supervisor 

Clerk 

R.3 Occupational Medical Dose 

No information regarding occupational medical dose specific to ALCOA-PA was found. 

Information to be used in dose reconstructions for which no specific information is 

available is provided in ORAUT-OTIB-0006, the dose reconstruction project technical 

information bulletin covering diagnostic x-ray procedures. 
Document No. Battelle-TBD-6000; 

Appendix R 

Revision No. 0 Effective Date: 4/30/2007 Page 3 

R.4 Occupational Internal Dose 

No data was found in the Site Research database related to occupational internal dose 

during AEC work. The work performed at ALCOA-PA involved canning uranium slugs. 

Therefore, the internal doses are derived using air concentration values in the TBD for 

"Slug Production and Canning.” 

Tables R.1 and R.2 present these internal dose estimates in pCi per calendar day to be 

used for each calendar year listed. 

R.5 Occupational External Dose 

No data was found in the Site Research database related to occupational external dose 

during AEC work. The work performed at ALCOA-PA involved canning uranium slugs. 

Therefore, the external dose values in the TBD for "Slug Production and Canning" should 

be used. 

Tables R.3 and R.4 present these external dose estimates in mrem per calendar day to be 

used for each calendar year listed. 

R.6 Residual Contamination 

A FUSRAP survey of ALCOA-PA was conducted on November 12, 1991. The survey 

consisted of direct readings of gamma, alpha and beta-gamma levels and dust samples for 

radionuclide analysis. The results demonstrated no measured levels above DOEFUSRAP guidelines and radionuclide distributions were not significantly different from 

typical background levels for the area. Therefore, no exposure to residual contamination 

is assumed after 1991. (Reference 16445, Page 10). A potential exists, however, for 

exposure due to residual contamination between 1946 and 19912

, so this is evaluated 

assuming deposition of the plant floor high air concentration and resuspension assuming 

no cleanup. 

R.7 References 

1. DOE Office of Health, Safety and Security, EEOICPA web site. 

http://www.hss.energy.gov/healthsafety/fwsp/advocacy/faclist/findfacility.cfm 

2. Report on Residual Radioactive and Beryllium Contamination at Atomic Weapons 

Employer Facilities and Beryllium Vender Facilities. 

http://www.cdc.gov/niosh/ocas/pdfs/tbd/rescon/rcontam1206.pdf 
Document No. Battelle-TBD-6000; Appendix R Revision No. 0 Effective Date: 4/30/2007 

Table R.1 INTERNAL DOSE PATHWAYS - Inhalation of Airborne Radionuclides Assumptions: Operational Period Daily Weighted Average Air Concentration, Plant Floor High: 198 dpm/m3

Residual Period Daily Weighted Average Air Concentration: 1.28 dpm/m3

TBD GSD Default is 5 Conversion Factor: 2.22 dpm/pCi Breathing Rate: 1.2 m^3/hour All intakes and doses assume full-time employment for the given year. 

Job Category Year 

Operation 

Phase Hr/Yr 

Relevant 

Nuclide 

Intake 

(pCi/d) GSD TBD Reference or Resear

Plant Floor High 1943 Operations 2400 U234 7.04E+02 5 Based on Metal TBD for Slug Plant Floor High 1944 Operations 2400 U234 7.04E+02 5 Based on Metal TBD for Slug Plant Floor High 1945 Operations 2400 U234 7.04E+02 5 Based on Metal TBD for Slug Plant Floor High 1946 - '50 Residual 2400 U234 4.56E+00 5 Based on resuspension of 194Plant Floor High 1951 - '55 Residual 2200 U234 4.18E+00 5 Based on resuspension of 194Plant Floor High '56 - 11/91 Residual 2000 U234 3.80E+00 5 Based on resuspension of 194Plant Floor Low 1943 Operations 2400 U234 3.52E+02 5 Based on Metal TBD for Slug Plant Floor Low 1944 Operations 2400 U234 3.52E+02 5 Based on Metal TBD for Slug Plant Floor Low 1945 Operations 2400 U234 3.52E+02 5 Based on Metal TBD for Slug Plant Floor Low 1946 - '50 Residual 2400 U234 4.56E+00 5 Based on resuspension of 194Plant Floor Low 1951 - '55 Residual 2200 U234 4.18E+00 5 Based on resuspension of 194Plant Floor Low '56 - 11/91 Residual 2000 U234 3.80E+00 5 Based on resuspension of 194Supervisor 1943 Operations 2400 U234 1.76E+02 5 Based on Metal TBD for Slug Supervisor 1944 Operations 2400 U234 1.76E+02 5 Based on Metal TBD for Slug Supervisor 1945 Operations 2400 U234 1.76E+02 5 Based on Metal TBD for Slug Supervisor 1946 - '50 Residual 2400 U234 4.56E+00 5 Based on resuspension of 194Supervisor 1951 - '55 Residual 2200 U234 4.18E+00 5 Based on resuspension of 194Supervisor '56 - 11/91 Residual 2000 U234 3.80E+00 5 Based on resuspension of 194Clerical 1943 Operations 2400 U234 1.76E+01 5 Based on Metal TBD for Slug Clerical 1944 Operations 2400 U234 1.76E+01 5 Based on Metal TBD for Slug Clerical 1945 Operations 2400 U234 1.76E+01 5 Based on Metal TBD for Slug Clerical 1946 - '50 Residual 2400 U234 4.56E+00 5 Based on resuspension of 194
Document No. Battelle-TBD-6000; Appendix R Revision No. 0 Effective Date: 4/30/2007 

Job Category Year 

Operation 

Phase Hr/Yr 

Relevant 

Nuclide 

Intake 

(pCi/d) GSD TBD Reference or Resear

Clerical 1951 - '55 Residual 2200 U234 4.18E+00 5 Based on resuspension of 194Clerical '56 - 11/91 Residual 2000 U234 3.80E+00 5 Based on resuspension of 194
Document No. Battelle-TBD-6000; Appendix R Revision No. 0 Effective Date: 4/30/2007 

Table R.2 INTERNAL DOSE PATHWAYS - Ingestion of Airborne Radionuclides Assumptions: Air Concentration to Intake Conversion Factor: 3.06E-05 (M^3/d)/(hr/y) - see 7.1.6 TBD-6000 Deposition velocity: 0.00075 m/s Resuspension Factor: 1.00E-06 1/m 

Job Category Year 

Operation 

Phase Hr/Yr 

Relevant 

Nuclide 

Intake 

(pCi/d) GSD TBD Reference or Resear

Plant Floor High 1943 Operations 2400 U234 6.55E+00 5 Based on Metal TBD for Slug Plant Floor High 1944 Operations 2400 U234 6.55E+00 5 Based on Metal TBD for Slug Plant Floor High 1945 Operations 2400 U234 6.55E+00 5 Based on Metal TBD for Slug Plant Floor High 1946 - '50 Residual 2400 U234 4.25E-02 5 Based on resuspension of 194Plant Floor High 1951 - '55 Residual 2200 U234 3.89E-02 5 Based on resuspension of 194Plant Floor High '56 - 11/91 Residual 2000 U234 3.54E-02 5 Based on resuspension of 194Plant Floor Low 1943 Operations 2400 U234 3.28E+00 5 Based on Metal TBD for Slug Plant Floor Low 1944 Operations 2400 U234 3.28E+00 5 Based on Metal TBD for Slug Plant Floor Low 1945 Operations 2400 U234 3.28E+00 5 Based on Metal TBD for Slug Plant Floor Low 1946 - '50 Residual 2400 U234 4.25E-02 5 Based on resuspension of 194Plant Floor Low 1951 - '55 Residual 2200 U234 3.89E-02 5 Based on resuspension of 194Plant Floor Low '56 - 11/91 Residual 2000 U234 3.54E-02 5 Based on resuspension of 194Supervisor 1943 Operations 2400 U234 1.64E+00 5 Based on Metal TBD for Slug Supervisor 1944 Operations 2400 U234 1.64E+00 5 Based on Metal TBD for Slug Supervisor 1945 Operations 2400 U234 1.64E+00 5 Based on Metal TBD for Slug Supervisor 1946 - '50 Residual 2400 U234 4.25E-02 5 Based on resuspension of 194Supervisor 1951 - '55 Residual 2200 U234 3.89E-02 5 Based on resuspension of 194Supervisor '56 - 11/91 Residual 2000 U234 3.54E-02 5 Based on resuspension of 194Clerical 1943 Operations 2400 U234 1.64E-01 5 Based on Metal TBD for Slug Clerical 1944 Operations 2400 U234 1.64E-01 5 Based on Metal TBD for Slug Clerical 1945 Operations 2400 U234 1.64E-01 5 Based on Metal TBD for Slug Clerical 1946 - '50 Residual 2400 U234 4.25E-02 5 Based on resuspension of 194Clerical 1951 - '55 Residual 2200 U234 3.89E-02 5 Based on resuspension of 194Clerical '56 - 11/91 Residual 2000 U234 3.54E-02 5 Based on resuspension of 194
Document No. Battelle-TBD-6000; Appendix R Revision No. 0 Effective Date: 4/30/2007 

Table R.3 EXTERNAL DOSE PATHWAYS - Whole Body Asumptions: Submersion Dose Conversion Factor: 2.462E-09 mrem/h/dpm/m^3 Deposition velocity: 0.0008 Contaminated Surface Dose Conversion Factor: 5.615E-10 mrem/h/dpm/m^2 All external dose from estimated exposure to uranium slugs Residual period: Assume no handling of U metal - only exposure is from residual contamination on floor and in air 

Job Category Year 

Operation 

Phase Hr/Yr 

Relevant 

Nuclide 

External 

Whole 

Body 

(mR/d) GSD TBD Reference or Resear

Plant Floor High 1943 Operations 2400 U234 3.49E-01 5 Generic Metal TBD, Section 6Plant Floor High 1944 Operations 2400 U234 3.49E-01 5 Generic Metal TBD, Section 6Plant Floor High 1945 Operations 2400 U234 3.49E-01 5 Generic Metal TBD, Section 6Plant Floor High 1946 - '50 Residual 2400 U234 3.07E-05 5 Generic Metal TBD, Section 6Plant Floor High 1951 - '55 Residual 2200 U234 2.58E-05 5 Generic Metal TBD, Section 6Plant Floor High '56 - 11/91 Residual 2000 U234 2.13E-05 5 Generic Metal TBD, Section 6Plant Floor Low 1943 Operations 2400 U234 1.75E-01 5 Generic Metal TBD, Section 6Plant Floor Low 1944 Operations 2400 U234 1.75E-01 5 Generic Metal TBD, Section 6Plant Floor Low 1945 Operations 2400 U234 1.75E-01 5 Generic Metal TBD, Section 6Plant Floor Low 1946 - '50 Residual 2400 U234 3.07E-05 5 Generic Metal TBD, Section 6Plant Floor Low 1951 - '55 Residual 2200 U234 2.58E-05 5 Generic Metal TBD, Section 6Plant Floor Low '56 - 11/91 Residual 2000 U234 2.13E-05 5 Generic Metal TBD, Section 6Supervisor 1943 Operations 2400 U234 1.84E-02 5 Generic Metal TBD, Section 6Supervisor 1944 Operations 2400 U234 1.84E-02 5 Generic Metal TBD, Section 6Supervisor 1945 Operations 2400 U234 1.84E-02 5 Generic Metal TBD, Section 6Supervisor 1946 - '50 Residual 2400 U234 3.07E-05 5 Generic Metal TBD, Section 6Supervisor 1951 - '55 Residual 2200 U234 2.58E-05 5 Generic Metal TBD, Section 6Supervisor '56 - 11/91 Residual 2000 U234 2.13E-05 5 Generic Metal TBD, Section 6Clerical 1943 Operations 2400 U234 1.18E-04 5 Generic Metal TBD, Section 6Clerical 1944 Operations 2400 U234 1.18E-04 5 Generic Metal TBD, Section 6Clerical 1945 Operations 2400 U234 1.18E-04 5 Generic Metal TBD, Section 6
Document No. Battelle-TBD-6000; Appendix R Revision No. 0 Effective Date: 4/30/2007 

Job Category Year 

Operation 

Phase Hr/Yr 

Relevant 

Nuclide 

External 

Whole 

Body 

(mR/d) GSD TBD Reference or Resear

Clerical 1946 - '50 Residual 2400 U234 3.07E-05 5 Generic Metal TBD, Section 6Clerical 1951 - '55 Residual 2200 U234 2.58E-05 5 Generic Metal TBD, Section 6Clerical '56 - 11/91 Residual 2000 U234 2.13E-05 5 Generic Metal TBD, Section 6
Document No. Battelle-TBD-6000; Appendix R Revision No. 0 Effective Date: 4/30/2007 

Table R.4 EXTERNAL DOSE PATHWAYS - Skin Assumptions: All assumptions from TBD-6000 Section 6.3 Operational Period: Non-penetrating dose to skin 115 mR/hour (hands and forearms) 10.4 mR/hour (other) 

Plant Floor High: Assume hands in contact with metal 50% of time. Other skin is 100% of dose rate at 1-f

Plant Floor Low: 50% of Plant Floor High Supervisor: assume 10% of Plant Floor Low for time in contact with metal Clerical: assume no handling of U metal. 

Residual Period: Non-penetrating dose to skin 3.9E-06 mr/hour 

Assume no handling of U metal. Assume 10x the photon whole body dose rate 

Job Category Year 

Operation 

Phase Hr/Yr 

Relevant 

Nuclide 

Hands & 

Forearms 

(mR/d) 

Other 

Skin 

(mR/d) GSD TBD Referen

Plant Floor High 1943 Operations 2400 U234 7.56E+02 6.84E+01 5 Generic Metal TBPlant Floor High 1944 Operations 2400 U234 7.56E+02 6.84E+01 5 Generic Metal TBPlant Floor High 1945 Operations 2400 U234 7.56E+02 6.84E+01 5 Generic Metal TBPlant Floor High 1946 - '50 Residual 2400 U234 3.07E-04 3.07E-04 5 Generic Metal TBPlant Floor High 1951 - '55 Residual 2200 U234 2.58E-04 2.58E-04 5 Generic Metal TBPlant Floor High '56 - 11/91 Residual 2000 U234 2.13E-04 2.13E-04 5 Generic Metal TBPlant Floor Low 1943 Operations 2400 U234 3.78E+02 3.42E+01 5 Generic Metal TBPlant Floor Low 1944 Operations 2400 U234 3.78E+02 3.42E+01 5 Generic Metal TBPlant Floor Low 1945 Operations 2400 U234 3.78E+02 3.42E+01 5 Generic Metal TBPlant Floor Low 1946 - '50 Residual 2400 U234 3.07E-04 3.07E-04 5 Generic Metal TBPlant Floor Low 1951 - '55 Residual 2200 U234 2.58E-04 2.58E-04 5 Generic Metal TBPlant Floor Low '56 - 11/91 Residual 2000 U234 2.13E-04 2.13E-04 5 Generic Metal TBSupervisor 1943 Operations 2400 U234 3.78E+01 3.42E+00 5 Generic Metal TBSupervisor 1944 Operations 2400 U234 3.78E+01 3.42E+00 5 Generic Metal TBSupervisor 1945 Operations 2400 U234 3.78E+01 3.42E+00 5 Generic Metal TBSupervisor 1946 - '50 Residual 2400 U234 3.07E-04 3.07E-04 5 Generic Metal TBSupervisor 1951 - '55 Residual 2200 U234 2.58E-04 2.58E-04 5 Generic Metal TBSupervisor '56 - 11/91 Residual 2000 U234 2.13E-04 2.13E-04 5 Generic Metal TBClerical 1943 Operations 2400 U234 0.00E+00 0.00E+00 5 Generic Metal TBClerical 1944 Operations 2400 U234 0.00E+00 0.00E+00 5 Generic Metal TB
Document No. Battelle-TBD-6000; Appendix R Revision No. 0 Effective Date: 4/30/2007 

Job Category Year 

Operation 

Phase Hr/Yr 

Relevant 

Nuclide 

Hands & 

Forearms 

(mR/d) 

Other 

Skin 

(mR/d) GSD TBD Referen

Clerical 1945 Operations 2400 U234 0.00E+00 0.00E+00 5 Generic Metal TBClerical 1946 - '50 Residual 2400 U234 3.07E-04 3.07E-04 5 Generic Metal TBClerical 1951 - '55 Residual 2200 U234 2.58E-04 2.58E-04 5 Generic Metal TBClerical '56 - 11/91 Residual 2000 U234 2.13E-04 2.13E-04 5 Generic Metal TB